Ramsey RPH-40000 User Manual

OPERATING, SERVICE AND

MAINTENANCE MANUAL

MODEL RPH-40,000

INDUSTRIAL PLANETARY WINCH

WITH AIR TENSIONER AND 2 SPEED MOTOR

CAUTION: READ AND UNDERSTAND THIS MANUAL BEFORE INSTALLATION AND

OPERATION OF WINCH. SEE WARNINGS!

TABLE OF CONTENTS

INTRODUCTION............................................................................................................... 1

WARRANTY INFORMATION ........................................................................................... 1

SPECIFICATIONS ............................................................................................................ 1

WARNINGS ...................................................................................................................... 1

HYDRAULIC SYSTEM REQUIREMENTS........................................................................ 2

PERFORMANCE CHARTS .............................................................................................. 2

WINCH OPERATION........................................................................................................ 3

CLUTCH OPERATION ..................................................................................................... 3

CABLE INSTALLATION.................................................................................................... 3

MAINTENANCE ................................................................................................................4

TROUBLE SHOOTING GUIDE......................................................................................... 4

INSTRUCTIONS FOR OVERHAUL ............................................................................. 5-12

MOUNTING CONFIGURATIONS ................................................................................... 12

DIMENSIONAL DRAWING ............................................................................................. 14

PARTS LIST AND PART DRAWING .........................................................................15-17

LIMITED WARRANTY ...................................................................................... Back cover

…

RAMSEY HYDRAULIC PLANETARY WINCH MODEL RPH 40,000

PLEASE READ THIS MANUAL CAREFULLY

This manual contains useful ideas in obtaining the most efficient operation from your Ramsey Winch, and safety procedures one needs to know before operating a Ramsey Winch. Do not operate this winch until you have carefully read and understand the "WARNINGS" and "OPERATION" sections of this manual.

WARRANTY INFORMATION

Ramsey Winches are designed and built to exacting specifications. Great care and skill go into every winch we make. If the need should arise, warranty procedure is outlined on the back of your self-addressed postage paid warranty card. Please read and fill out the enclosed warranty card and send it to Ramsey Winch Company. If you have any problems with our winch, please follow instructions for prompt service on all warranty claims. Refer to back page for limited warranty.

SPECIFICATIONS* (LOW SPEED MODE)

Rated Line Pull (lbs.) 40,000

(Kg.) 18,100

Gear Reduction 51.35:1

Weight (without cable)

LAYER OF CABLE *Rated line pull

per layer

*Cable Capacity

*Line Speed (at 17 GPM)

* These specifications are based on recommended wire rope of .75 inch dia. extra improved plow steel or equivalent

NOTE: The rated line pulls shown are for the winch only. Consult the wire rope manufacturer for wire rope ratings.

…………………………………………………………

lbs. 40,000 33,500 28,800 25,300 22,500 20,300 Kg. 18,100 15,100 13,000 11,400 10,200 9,200 ft. 25 55 95 135 185 235

m 7 1628415671 FPM 1618.721242729 MPM 4.8 5.6 6.3 7.2 8.2 8.8

…………………………………………………… ……………………………………………………

…………………………………………

123456

700 lbs. (318 Kg)

WARNINGS:

CLUTCH MUST BE TOTALLY ENGAGED BEFORE STARTING THE WINCHING OPERATION. DO NOT START WINCH MOTOR BEFORE ENGAGING CLUTCH. DO NOT DISENGAGE CLUTCH UNDER LOAD. STAY OUT FROM UNDER AND AWAY FROM RAISED LOADS. STAND CLEAR OF CABLE WHILE PULLING. DO NOT TRY TO GUIDE CABLE. DO NOT EXCEED MAXIMUM LINE PULL RATINGS SHOWN IN TABLE. DO NOT USE WINCH TO LIFT, SUPPORT, OR OTHERWISE TRANSPORT PEOPLE. A MINIMUM OF 5 WRAPS OF CABLE AROUND THE DRUM BARREL IS NECESSARY TO HOLD THE LOAD.

CABLE ANCHOR IS NOT DESIGNED TO HOLD LOAD.

HYDRAULIC SYSTEM REQUIREMENTS

Refer to the performance charts to properly match your hydraulic system to RPH-40000 winch performance. The charts consist of:

(1) Line pull (lb.) first layer vs. working pressure (PSI) and (2) Line speed (FPM) first layer vs. flow (GPM).

Performance is based on a motor displacement of 9.6 cubic inches with 17 GPM maximum flow rate. See page 13 for motor port size.

TYPICAL LAYOUT

DUAL-A & B PORT CONTROL

WITH BRAKE RELEASE SHUTTLE

MOTOR

BRAKE

PORT

PUMP

PERFORMANCE CHARTS

(BASED ON 9.6 CU. IN./REV MOTOR)

40000

35000

30000

25000

CONTROL VALVE

3 POSITION

4 WAY VALVE

(MOTOR SPOOL)

20000

LINE PULL (Lbs.)

15000

10000

DELTA P @ MOTOR (PSI)

LINE SPEED (Ft/Min)

2500200015001000500

2800

FLOW (GPM)

WINCH OPERATION

Before operating the winch for the first time, remove the cover from the breather vent at the back of the air

cylinder and the relief fitting on top of the clutch housing.

The best way to get acquainted with how your winch operates is to make test runs before you use it. Plan your test in advance. Remember, you hear your winch, as well as see it operate. Learn to recognize the sounds of a light steady pull, a heavy pull, and sounds caused by load jerking or shifting. Gain confidence in operating your winch and its use will become second nature with you.

The uneven spooling of cable, while pulling a load, is not a problem, unless there is a cable pileup on one end of drum. If this happens, reverse the winch to relieve the load and move your anchor point further to the center of the vehicle. After the job is done you can unspool and rewind for a neat lay of the cable.

CLUTCH OPERATION

To engage clutch:

1. Move the clutch control valve to the “clutch engaged” position.

2. Anytime the temperature is below freezing, run the motor in the “cable out” direction only until the drum starts to turn. In extreme cold temperatures (below 0o F/-18o C), pull out on the cable by hand only until

the drum starts to turn.

3. Wait at least 3 seconds for the clutch to fully engage, after which the winch is ready to winch in the cable.

WARNING: Do not attempt to engage the clutch by first running the winch motor and then moving the clutch control valve to the "clutch-engaged" position while the motor is running. Do not start picking up the load at the same time the clutch is being engaged.

To disengage clutch:

1. Run the winch in the "cable out" direction until the load is off the cable.

2. Move the clutch control valve to the "clutch-disengaged" position.

3. The cable may now be pulled off by hand.

CABLE INSTALLATION

Unwind cable by rolling it out along the ground to prevent kinking. Securely wrap end of wire rope, opposite

hook, with plastic or similar tape to prevent fraying.

2. Insert the end of cable, opposite hook end, into the hole in drum barrel. Secure cable to drum barrel, using

setscrew furnished with winch. TIGHTEN SETSCREW SECURELY.

3. Carefully run the winch in the “reel-in” direction. Keeping tension on end of cable, spool all the cable onto

the cable drum, taking care to form neatly wrapped layers.

MAINTENANCE

Adhering to the following maintenance schedule will keep your winch in top condition and performing as it should with a minimum of repair.

A. WEEKLY

1. Check the oil level and maintain it to the oil level plug. If oil is leaking out, determine location and repair.

Check the pressure relief plug in top of the gear housing. Be sure that it is not plugged.

Lubricate cable with light oil.

B. MONTHLY

1. Check the winch mounting bolts. If any are missing, replace them and securely tighten any that are

loose. Use grade 5 or better bolts.

2. Inspect the cable. If the cable has become frayed with broken strands, replace immediately.

C. ANNUALLY

1. Drain the oil from the winch annually or more often if winch is used frequently.

2. Fill the winch to the oil level plug with clean kerosene. Run the winch a few seconds with no load in the

reel in direction. Drain the kerosene from the winch.

3. Refill the winch to the oil level plug with all-purpose SAE 80W-140 gear oil.

4. Inspect frame and surrounding structure for cracks or deformation.

TROUBLESHOOTING GUIDE

CONDITIONS POSSIBLE CAUSE CORRECTION

OIL LEAKS FROM WINCH

1. Seals damaged or worn.

2. Too much oil. 2. Drain excess oil. Refer to OPERATION.

1. Replace seal.

3. Damaged gaskets. 3. Replace gaskets.

1. Low flow rate 1. Check flow rate. Refer to HYDRAULIC

WINCH RUNS TOO SLOW

2. Hydraulic motor

SYSTEMS performance chart page 2.

2. Replace motor.

worn out.

CABLE DRUM WILL NOT FREESPOOL

1. Clutch not disengaged

1. Check air pressure to clutch cylinder: 100 PSI Minimum required. Refer to page 13 for port location.

BRAKE WLL NOT RELEASE

1. Brake line disconnected or blocked.

1. Check brake function. Refer to page 12.

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